Means to prevent wound dressings from adhering to closure device

ABSTRACT

A wound dressing for use with a closure device is disclosed. The first and second base panels of the closure device are positioned on opposite lateral sides of a wound or incision. The base panels are coupled together to maintain wound or incision closure. A release liner is removed from a bottom surface of the wound dressing. The wound dressing is positioned over the closure device and the wound or incision. Exudate is absorbed by an absorbent material of the wound dressing through a porous strip of the wound dressing. The wound dressing is slightly larger than the closure device so that its perimeter area is adhered to the skin area around the closure device. Alternatively or in combination, the wound dressing is lightly adhered to the closure device and wound or incision area so that it can be removed without harming the underlying device and tissues.

CROSS-REFERENCE

This application is a divisional of U.S. patent application Ser. No.15/130,764, filed Apr. 15, 2016, now U.S. Pat. No. 10,123,801, whichclaims the benefit of U.S. Provisional Application No. 62/202,572, filedAug. 7, 2015, which application is incorporated herein by reference.

The subject matter of this application is related to the subject matterof the following U.S. patents and co-pending U.S. patent applications:application Ser. No. 13/414,176, filed 7 Mar. 2012 and issued as U.S.Pat. No. 9,179,914 on 10 Nov. 2015; application Ser. No. 14/958,803,filed 3 Dec. 2015; application Ser. No. 14/958,818, filed 3 Dec. 2015;application Ser. No. 14/851,059, filed 11 Sep. 2015; application Ser.No. 13/286,757, filed 1 Nov. 2011 and issued as U.S. Pat. No. 8,323,313on 4 Dec. 2012; application Ser. No. 14/625,366, filed 18 Feb. 2015;application Ser. No. 13/665,160, filed 31 Oct. 2012; application Ser.No. 14/180,564, filed 14 Feb. 2014 and issues as U.S. Pat. No. 9,089,328on 28 Jul. 2015; and application Ser. No. 14/180,524 filed 14 Feb. 2014and issued as U.S. Pat. No. 9,050,086 on 9 Jun. 2015 which areincorporated herein by reference.

The subject matter of this application is related to the subject matterof the following PCT applications: application Ser. No.PCT/US2010/000430, filed 3 May 2010; application Ser. No.PCT/US2015/049671, filed 11 Sep. 2015; application Ser. No.PCT/US2012/062820, filed 31 Oct. 2013; application Ser. No.PCT/US2013/067563, filed 30 Oct. 2013; application Ser. No.PCT/US2014/016587, filed 14 Feb. 2014; application Ser. No.PCT/US2015/010188, filed 5 Jan. 2015; and application Ser. No.PCT/US2015/028066, filed 28 Apr. 2015 which are incorporated herein byreference.

BACKGROUND

The present disclosure relates to medical devices, systems, and methodsfor wound closure. In particular, devices, systems, and methods forpreventing undesired adherence of wound dressings to an applied closuredevice are disclosed.

Many surgical incision or wound closure devices comprise first andsecond base panels which are adhered to the skin on the two lateralsides adjacent the incision or wound. The base panels are then laterallycoupled to one another (such as with tensioning elements) to close andmaintain closure of the wound or incision. Such wound closure devicesare disclosed by U.S. patent application Ser. No. 13/414,176 (U.S. Pat.No. 9,179,914), Ser. Nos. 14/958,803, 14/958,818, 14/851,059, 13/286,757(U.S. Pat. No. 8,323,313), Ser. Nos. 14/625,366, 13/665,160, 14/180,564(U.S. Pat. No. 9,089,328), and Ser. No. 14/180,524 (U.S. Pat. No.9,050,086) and PCT application publication nos. PCT/US2010/000430,PCT/US2015/049671, PCT/US2012/062820, PCT/US2013/067563,PCT/US2014/016587, PCT/US2015/010188, and PCT/US2015/028066, which areincorporated herein by reference. Such closure devices are commerciallyavailable as the Zip® device available from Zipline Medical of Campbell,Calif.

After closure of the surgical incision or wound, many physicians,physician assistants, nurses, and other associate caregivers and medicalprofessionals typically apply a wound dressing to the incision or wound.The purpose of the wound dressing use may vary, but can include any orall of the following: absorption of wound exudate, minimizing infectionrisk, protecting the wound during bathing and other patient activities,and preventing patient visualization and/or tampering with the woundsite. Wound dressings may be applied immediately after surgical closure,or at any time during the post-surgical wound healing. Wound dressingsmay also be removed at any time during the post-surgical wound healingperiod, and replaced with a new dressing as needed.

Wound dressings can come in various shapes and configurations. Onecommon dressing configuration is the “island dressing” which comprisesof an absorbent central pad surrounded on all sides by a skin adhesive.Many commercially available dressings are available. Examples ofdressing types desired for use with closure devices include, but are notlimited to: Convatec Aquacel™ Ag, Smith & Nephew Opsite® Post-Op,Argentum Medical Silverlon®, and Mölnlycke Mepilex® Border.

Typically the central pad does not have a skin adhesive, though somebrands (e.g., Mölnlycke Mepilex® dressings) provide a low-tack adhesivesuch as silicone, across the pad. Other dressings may comprise of a thinpolyurethane-acrylic adhesive film laminate (e.g., 3M Tegaderm®) tocover and protect the wound. Dressings can also be fashioned by theuser, such as by applying gauze or Telpha pads to the wound and securingthem with tape or polyurethane-adhesive films. The wound dressing padand/or adhesive itself may or may not incorporate anti-microbialsubstances such as silver, chlorhexidine, and others well-known in theart. Pressure sensitive adhesives are typically used for adherence ofthe dressing to the skin, with the most common being derived fromacrylic, hydrocolloid, or silicone. Other skin adhesives may also beused that are readily available from commercial sources.

SUMMARY

Because many closure devices rely on adhesion to the skin to function,premature loss of adhesion can result in the wound not having sufficientclosure force and/or isolation from distraction forces to ensureadequate healing. Wound dressings applied over such closure devices maycontain skin adhesives that strongly adhere the wound dressing to theclosure device. Removal of the wound dressing can result in the closuredevice being removed from the skin before the wound is fully healed.Accordingly, it is desired to discourage adherence of the wound dressingto closure devices.

The present disclosure relates to devices, systems, and methods forprotecting closure devices from wound dressing adhesives. Protection ofthe outer perimeter of the closure device adhesive base panels (e.g.,those laminated with a polyurethane or polyethylene film) to preventpeel initiation from the dressing is desired. In many embodiments, theentire panel is protected. Protection of the tensioning elementscrossing the incision (e.g., molded straps and locks adhered to eachpanel) may be desirable, but may not be as critical since these elementsare often located under the non-adhesive pad of the wound dressing.

Aspects of the present disclosure provide methods of closing an incisionor wound. First and second base panels of a closure device may beprovided. The first and second base panels may be configured to adhereto tissue adjacent first and second lateral sides, respectively, of theincision or wound. The closure device may be coated with a low frictionor non-stick coating. A wound dressing may be positioned over the curedcoating and the closure device, with the closure device being adhered totissue. The cured coating may allow the wound dressing to be removedfrom the closure device while adherence of the first and second basepanels with the tissue is maintained.

The low friction or non-stick coating may comprise a non-stickfluoropolymer coating. The low friction or non-stick coating maycomprise a silicone compound, a silicone oil, or parylene. The closuredevice may be coated with the low friction or non-stick coating at athickness of 0.25 to 5.0 microns. The low friction or non-stick coatingmay be cured at a temperature of no more than 60° C., and in some cases,no more than 45° C. The cured coating may remain bound to the closuredevice after the wound dressing is removed. The cured coating may beremoved from the closure device concurrently with removal of the wounddressing. At least a portion of the closure device may be masked beforecoating the closure device with the low friction or non-stick coating.For instance, areas of the left and right base panels where adhesive ofthe panels are exposed may be masked. The low friction or non-stickcoating may comprise an anti-microbial coating. The cured coating may bestretchable.

Aspects of the present disclosure may also provide methods of closing anincision or wound. First and second base panels of a closure device maybe adhered to tissue adjacent first and second lateral sides,respectively, of the incision or wound. First and second sacrificialcover strips may be positioned over the first and second base panelsthat are adhered to the tissue. The first and second sacrificial coverstrips may be adhered to the first and second base panels, respectively.A wound dressing may be positioned over the first and second sacrificialcover strips that are adhered to the first and second base panels. Thewound dressing may adhere to the first and second sacrificial coverstrips. The first and second sacrificial covers may allow the wounddressing to be removed while leaving the closure device adhered to thetissue.

To position the first and second sacrificial cover strips over the firstand second base panels, perimeters of the first and second sacrificialcover strips may be extended over perimeters of the first and secondbase panels, respectively. One or more of the first or secondsacrificial cover strips may overlap full lengths of one or more of thefirst or second base panels, respectively. The first and secondsacrificial strips may comprise upper adhesive surfaces having a firstadhesive tack and lower adhesive surfaces having a second adhesive stackless than the first adhesive tack.

One or more of the first or second sacrificial cover strips may compriseone or more perforations, notches, or cutout spaces. One or more of thefirst or second sacrificial cover strips may comprise a polyurethanefilm layer. One or more of the first or second sacrificial cover stripsmay comprise a pressure sensitive adhesive layer. A release liner may beremoved from the first and second cover strips prior to the first andsecond cover strips being adhered to the first and second base panels.

Aspects of the present disclosure provide systems for closing anincision or wound. The system may comprise a closure device and asacrificial cover strip. The closure device may comprise first andsecond adherent base panels and a plurality of closure components tocouple the first and second adherent base panels to one another. Thesacrificial cover strip may comprise first and second sacrificial coverstrips having an adherent bottom surface and a release liner coupledthereto.

The perimeters of the first and second sacrificial cover strips may begreater than perimeters of the first and second adherent base panelssuch that when adhered thereto, the first and second sacrificial coverstrips can extend beyond the perimeters of the first and second adherentbase panels, respectively. The full lengths of the first and secondsacrificial cover strips may be greater than the full lengths of thefirst and second adherent base panels such that when adhered thereto,the first and second sacrificial cover strips can overlap the fulllengths of the first and second adherent base panels, respectively.

One or more of the first or second sacrificial cover strips may compriseone or more perforations, notches, or cutout spaces. One or more of thefirst or second sacrificial cover strips may comprise a pressuresensitive adhesive layer. The first and second sacrificial cover stripsmay comprise adherent upper surfaces having a first adhesive tack, andthe adherent bottom surfaces of the first and second sacrificial coverstrips may comprise a second adhesive tack less than the first adhesivetack. The first and second sacrificial cover strips may each comprise afirst polyurethane layer, a second polyurethane layer, and a pressuresensitive adhesive layer therebetween.

The closure device may be coated with a low friction or non-stickcoating that may be cured onto at least a portion of the closure deviceas described above and herein.

Aspects of the present disclosure provide devices for covering anincision or wound closure device adhered to skin adjacent a wound orincision. An exemplary device may comprise a strip, a support film, anda release liner. The strip may be configured for placement over theclosure device previously adhered to the skin adjacent the wound orincision. The support film may back the strip. The release liner may bereleasably attached to a bottom surface of the strip. The bottom surfaceof the strip may be adhesive. The support film may comprise an absorbentmaterial for absorbing exudate from the incision or wound. The strip maybe porous. The support film may comprise an adhesive bottom surface. Thesupport film may extend beyond the perimeter of the strip. The strip maycomprise comprises a first portion and a second portion separable fromone another.

Aspects of the present disclosure may provide methods of closing anincision or wound. First and second base panels of a closure device maybe provided. The first and second base panels may be configured toadhere to tissue adjacent first and lateral sides, respectively, of theincision or wound. A wound dressing may be positioned over the closuredevice and incision or wound. The wound dressing may absorb exudategenerated from the incision or wound between the first and second basepanels. The wound dressing may comprise an absorbent material and asupport film extending over the perimeter of the absorbent material. Aportion of the support film extending over the perimeter of theabsorbent material may be adhesive. The wound dressing may comprise acover strip coupled to the absorbent material and support film. Thecover strip may be porous. A release liner may be removed from the wounddressing prior to the wound dressing being positioned over the closuredevice and incision or wound.

Aspects of the present disclosure may provide systems for closing anincision or wound. The system may comprise a closure device and a wounddressing. The closure device may comprise first and second base panelsconfigured to adhere to tissue adjacent first and second sides,respectively, of the incision or wound. The first and second panels maybe releasably and adjustably attached to one another. The wound dressingmay be configured to extend over the first and second base panels toadhere to the tissue adjacent the first and second sides of the incisionor wound, thereby covering the closure device and incision or wound. Thewound dressing may be configured to be peeled off the tissue withoutremoving the first and second base panels adhered to the first andsecond sides, respectively, of the incision or wound. The wound dressingmay comprise an adhesive peripheral portion and an absorbent innerportion. The absorbent inner portion may be configured to be positionedover the incision or wound when the wound dressing is adhered to thetissue adjacent the first and second sides of the incision or wound toabsorb exudate therefrom. The wound dressing may comprise a releasableliner releasably adhered to a bottom surface of the wound dressing. Thewound dressing may comprise first and second parts axially separablefrom one another.

INCORPORATION BY REFERENCE

All publications, patents, and patent applications mentioned in thisspecification are herein incorporated by reference to the same extent asif each individual publication, patent, or patent application wasspecifically and individually indicated to be incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the present disclosure are set forth withparticularity in the appended claims. A better understanding of thefeatures and advantages of the present disclosure will be obtained byreference to the following detailed description that sets forthillustrative embodiments, in which the principles of the presentdisclosure are utilized, and the accompanying drawings of which:

FIG. 1A shows a perspective view of a surgical incision or wound closuredevice, according to many embodiments.

FIG. 1B shows a perspective view of the closure device of FIG. 1Aprovided with additional lateral skirts, according to many embodiments.

FIG. 1C shows a perspective view of an elongated closure device similarto that in FIG. 1A and additionally a magnified view showing its lateraltie assemblies.

FIG. 1D shows an exploded view of a portion of an incision closureappliance, according to many embodiments.

FIG. 1E1 shows a perspective view of a cover for the incision closureappliances, according to many embodiments.

FIG. 1E2 shows an exploded view of the cover of FIG. 1E1.

FIG. 1F1 shows an exploded view of an incision closure applianceassembly comprising the incision closure appliance of FIG. 1D and thecover of FIG. 1E1, according to many embodiments.

FIG. 1F2 shows a perspective view of the incision closure applianceassembly of FIG. 1F1 adhered onto the skin of a patient, according tomany embodiments.

FIG. 1F3 shows a top view of the elastomeric reinforcement layer of thecover of FIG. 1E1.

FIG. 1G1 shows a perspective view of the incision closure applianceassembly of FIG. 1F1 adhered onto the skin of a patient in accordancewith the principles of the present disclosure.

FIG. 1G2 shows a sectional schematic diagram of the incision closureappliance of FIG. 1F1 adhered onto the skin of a patient, according tomany embodiments.

FIGS. 1H1, 1H2, and 1H3 illustrate a method of applying the incisionclosure appliance assembly of FIG. 1F1 on the skin of a patient,according to many embodiments.

FIGS. 1I1, 1I2, 1I3, 1I4, and 1I5 illustrate embodiments of a cover forwound dressings and incision closure appliances, according to manyembodiments.

FIG. 2 shows a perspective view of a closure device similar to that inFIG. 1C provided with sacrificial cover strips and additionally amagnified view showing lateral notches of the sacrificial cover strip,according to embodiments of the present disclosure.

FIG. 3A shows a perspective view of a closure device and sacrificialcover strip assembly, according to many embodiments.

FIG. 3B shows an exploded view of the closure device and sacrificialcover assembly of FIG. 3A.

FIG. 4A shows a perspective view of a closure device and sacrificialcover strip assembly, according to many embodiments.

FIG. 4B shows an exploded view of the closure device and sacrificialcover strip assembly of FIG. 4A.

FIG. 4C shows a magnified view of the closure device and sacrificialcover strip assembly of FIG. 4A showing lateral notches of thesacrificial cover strip, according to embodiments of the presentdisclosure.

FIG. 5 shows an exploded view of the closure device and sacrificialcover strip assembly of FIG. 4, including views of the different layersof the sacrificial cover strips.

FIG. 6A shows a perspective view of a sacrificial cover strip assembly,according to many embodiments.

FIG. 6B shows an exploded view of the sacrificial cover strip assemblyof FIG. 6A.

FIG. 6C shows apertures of the adhesive layer of the sacrificial coverstrip assembly of FIG. 6A.

FIG. 7A shows a perspective view of a sacrificial cover strip assembly,according to many embodiments.

FIG. 7B shows an exploded view of the sacrificial cover strip assemblyof FIG. 7A.

FIG. 8A shows a perspective view of a sacrificial cover strip assembly,according to many embodiments.

FIG. 8B shows an exploded view of the sacrificial cover strip assemblyof FIG. 8A.

FIG. 9A shows a perspective view of a modular wound dressing assemblywith a protective layer, according to many embodiments.

FIG. 9B shows an exploded view of the modular wound dressing assembly ofFIG. 9A.

FIG. 9C shows placements of the modular wound dressing assembly of FIG.9A on a knee.

DETAILED DESCRIPTION

The apparatus and methods of the present disclosure can be used duringboth the formation and the closure of surgical incisions made to apatient's skin or other tissue during surgical procedures or wounds ingeneral. As described hereinafter, the direction of the incision orwound will define both “axial” and “lateral” directions as those termsare used herein. Most incisions will be made along a generally straightline which will define the axial direction. The lateral direction willgenerally be across the axial direction, typically but not necessarilybeing perpendicular or normal to the axial direction. Most incisionswill be generally linear but in some cases the incisions could be curvedor have other geometries. The term “axial” will then apply to thedirection of the incision at any particular location, resulting inlateral directions which could also vary.

Referring now to FIGS. 1A-1C, a closure device 100 usable withembodiments of the present disclosure is shown. The closure device orbase assembly 100 may comprise a right base panel 102 and a left basepanel 104. The right base panel 102 may comprise an upper layer 106 anda lower layer 108. Similarly, the left base panel 104 may comprise anupper layer 110 and a lower layer 112. The upper layers 106, 110 willtypically be flexible but stiff enough securely close tissue andminimize disruption of the incision and surrounding tissue. The upperlayers 106, 110 may comprise a plastic layer made of rubber, latex,polyurethane, silicone, a thermoplastic elastomer, a woven fabric, aspun fabric, or similar materials. The adhesive bottom layers 108, 112will typically be flexible and more elastic than the upper layers 106,110 to follow any movement of the underlying skin and tissue to maintainadhesion, minimize blistering, and otherwise reduce irritation. Theadhesive bottom layers 108, 112 may comprise a hydrophilic adhesivematerial such as a hydrocolloid, a hydrogel, an acrylic polymer, poly(ethylene glycol), and the like.

The right and left base panels 102, 104 may comprise structures tofacilitate and limit axial and lateral stretching of the base assembly100. These structures may also evenly distribute the closure forceexerted on an incision and may be disposed on the base assembly 100along its axial length. The right base panel 102 may comprise one ormore right force distribution structures or axial supports 114. Eachright axial support 114 may comprise an axial support portion or spine114 a and two lateral support portions 114 b coupled to the axial endsof the spine 114 a. Together, the spine 114 a and the two lateralsupport portions 114 b form a C-shape which in some embodiments can openaxially to a degree to facilitate axial stretching of the right basepanel 102 between two laterally adjacent lateral support portions 114 bof adjacent supports 114 while limiting the axial stretching between thetwo lateral support portions 114 b of a single support 114. In manyembodiments, the C-shaped axial support 114 is only flexible enough toallow flexing vertically but is stiff to minimize axial and lateralstretching. The right axial supports 114 may be outward facing which mayhelp to distribute any mechanical load against the tissue closure to theincision between the right and left base panels 102, 104. Similarly, theleft base panel 104 may comprise one or more left force distributionstructures or axial supports 116. Each left axial support 116 maycomprise an axial support portion or spine 116 a and two lateral supportportions 116 b coupled to the axial ends of the spine 116 a. Together,the spine 116 a and the two lateral support portions 116 b form aC-shape which in some embodiments can open axially to a degree tofacilitate axial stretching of the left base panel 102 between twolaterally adjacent lateral support portions 116 b of adjacent supports116 while limiting the axial stretching between the two lateral supportportions 116 b of a single support 116. In many embodiments, theC-shaped axial support 116 is only flexible enough to allow flexingvertically but is stiff to minimize axial and lateral stretching. Theleft axial supports 116 may be outward facing which may help todistribute any mechanical load against the tissue closure to theincision between the right and left base panels 102, 104.

As shown in FIG. 1B, the base panel assembly 100 may further compriseskirts 124 and 126. The skirts 124, 126 may be similar to the thin baseassembly covers described below. For example, each skirt 124, 126 maycomprise a 0.001 inch thick urethane film coupled to a 0.002 inch thickacrylic adhesive. The adhesive may be applied to the whole under-surfaceof the skirts 124, 126 or may just to the region of the skirts 124, 126beyond the base panels 102 or 104. During construction of the base panelassembly 100, the skirts 124, 126 may be applied directly over all or aportion of the adhesive layers 108, 112, respectively. The skirts 124,126 may be applied in place of, or in addition to, the thin film upperlayers 106, 110, respectively. Release liners as described herein mayfurther be provided to line the adhesive under-surface of the skirts124, 126. The skirts 124, 126 may extend beyond the outer border of thebase panels 102, 104, respectively, by 8 mm or in a range of 1 to 20 mm,for example, but does not span across the lateral area between the basepanels 102, 104 to improve the ability to visualize and/or clean theincision site. Thus, the skirts 124, 126 may help provide additionaladhesive support and/or creep reduction to the adhesive layers 108, 112of the base panels 102, 104 without having to align and place a separatecover or cover sheet over the base panel assembly 100. Aftermanufacturing, the skirts 124, 126 are typically already preciselyaligned relative to the base panels 102, 104. A separate cover or coversheet as described herein may still be used to prevent tampering of theincision site and components of the base panel assembly 100. As theskirts 124, 126 already laterally extend over the base panels 102, 104,respectively, such a separate cover or cover sheet may not requireprecise placement relative to the base panel assembly 100 and could bemore narrow compared with other covers or cover sheets described herein.

One or more perforations 118 may be provided in-between axially adjacentright axial supports 114 on right panel 102 to facilitate the axialand/or lateral stretching of the right base panel 102. The perforations118 may be all the way through the upper and lower layers 106, 108 toprovide aeration to the underlying tissue or may only be present on theupper layer 106. Similarly, one or more perforations 120 may be providedin-between axially adjacent left axial supports 116 on left panel 104 tofacilitate the axial and/or lateral stretching of the base panel 102.The perforations 120 may be all the way through the upper and lowerlayers 110, 112 to provide aeration to the underlying tissue or may onlybe present on the upper layer 110. There may only be a singleperforation 118 or 120 between the axial supports 114 or 118. There maybe a plurality of perforations 118 or 120 in a lateral line between theaxial supports 114 or 118. The perforations 118, 120 may also reduce thestress incurred as the skin stretches radially outward from the incisionsuch as during joint articulation and swelling.

A plurality of perforations 118, 120 may, for example, be providedin-between the axial ends of the right and/or left axial supports 114,116. A plurality of axially-aligned perforations may be provided suchthat at least the upper and lower layers 110, 112 of the base panels102, 104, respectively, may break into separate segments when axiallystretched. In some instances, during the wear duration of the device100, the perforations 118, 120 may allow the layers 106 and 108 of rightpanel 102 and the layers 110 and 112 of left panel 104 to completelydivide and separate at the perforation line. The ability to completelydivide and separate further allows the skin to stretch axially asneeded, with the elongation allowed (and limited) by the linkages ofaxial supports 114 and 116 and closure components 122 discussed below.As discussed herein, a flexible, compliant cover may be applied over thebase panels 102, 104 after the incision is closed. The cover may furtherserve to provide (and limit) axial and lateral movement of the basestructure 100. Alternatively or in combination, one or more of the rightor left base panels 102, 104 may be laterally cut and separatedin-between the force distribution structures or axial supports 114, 116to facilitate the axial and/or lateral stretching of the right and/orleft base panels 102, 104.

To couple the right and left base panels 102, 104 laterally together andoptionally to tighten the right and left base panels 102, 104 againstone another, the base assembly 100 may further comprise a pluralitylateral closure components or tie assemblies 122. The lateral closurecomponents or tie assemblies 122 may comprise a ratchet mechanism. Thelateral tie assemblies 122 may couple laterally adjacent right and leftaxial supports 114, 116 together, typically at their axial ends. Asshown in FIGS. 1A-1C, the placement of the right and left axial supports114, 116 on the right and left panels 102, 104, respectively, may bestaggered or axially offset, and the right and left axial supports 114,116 may be C-shaped structures with lateral end portions 114 b, 116 bthat laterally face and align with one another (and are connected to oneanother by a lateral tie assembly 122). For example, the far end lateralportion 114 b of a first right axial support 114 may be laterallyaligned with the near end lateral portion 116 b of a first left axialsupport 116, the far end lateral portion 116 b of the first left axialsupport 116 may be laterally aligned with the near end lateral portion114 b of a second right axial support 114, and so forth. Thus, thelateral tie assemblies 122 and right and left axial supports 114, 116may be connected to one another to form a line of consecutive lateraltie assemblies 122 and right and left axial supports 114, 116, and thisline may have a serpentine arrangement that laterally spans the rightand left base panels 102, 104 (i.e., goes across the distance betweenthe right and left base panels 102, 104) as shown in FIGS. 1A-1C. Theserpentine arrangement of lateral tie assemblies 122 and right and leftaxial supports 114, 116 may one or more of evenly distribute the closureforces provided by the base assembly 100 on an incision, provide (andlimit) axial flexibility of the base assembly 100, and provide rigidityor stiffness to the base assemblies 100 to sufficiently close anincision and allow it to heal with minimized disruption and distension(i.e., provide lateral and axial stability). In many embodiments, thelateral supports 114, 116 are stiff so that the areas of the base panels102, 104 that are not covered with the lateral supports 114, 116stretch. Because these uncovered areas are offset from one another fromthe right base panel 102 to the left base panel 104, the tie assemblies122 may pivot axially from their anchor points as the incision isaxially stretched. Such axial pivoting of the tie assemblies 122 maybring the left and right panels 102, 104 closer together to maintain theclosure of the incision.

The material of the lateral tie assemblies 122 and the right and leftaxial supports 114, 116 may include, for example, a flexible, resilientplastic, typically a hard plastic, such as Nylon, Polypropylene,Polyethylene, Poly carbonate, and other thermoplastic polymers. Often,the lateral tie assemblies 122 and the right and left axial supports114, 116 may comprise a material less elastic than that of the right andleft base panels 102, 104. Thus, greater stiffness (and less elasticity)may be provided toward the top of base assemblies 100. In other words,there may be an elasticity gradient between the top and bottom of thebase assemblies 100. The tops of the base assembly 100 may besufficiently rigid or stiff so that the incision closure appliance, whenapplied to an incision and surrounding tissue, prevents movement oftissue laterally adjacent the appliance to not substantially distend thecovered incision and surrounding tissue. That is, movement of at least aportion of the applied incision closure appliance (e.g., a portion belowthe more stiff layers) is collective and does not disrupt the underlyingincision. And, the bottom of the base assembly 100 may be sufficientlyelastic such that blistering and adhesion loss due to movement of tissueadjacent the applied incision closure appliance are minimized. While aprimary function of lateral tie assemblies 122 may be to apply tensionto each base panel 102, 104 to hold the incision closed, in manyembodiments, the lateral tie assemblies 122 may also serve to providecolumnar strength so as to isolate the incision by minimizing effects ofcompression on (or bending/creasing along) the incision from distractionforces that could disrupt the incision edge alignment and apposition.The axial spacing, material property, and dimension of the lateral ties122 may be optimized for sufficient axial bending flexibility andlateral compression and bending support. In preferred embodiments, thespacing between ties 122 is 10 mm, the material of the ties 1422 isnylon, and the dimension is a round cross-section of 0.030 inch.

The base assembly 100 may be placed over an incision in the skin of apatient or subject's joint, such as the knee, for example. In incisionsplaced in proximity to articulating joints, the knee in particular,closure device or closure appliance integrity is often challenged by anumber of factors. These factors include longitudinal elongation,circumferential swelling, opening of the wound as articulation occurs,skin damage such as blistering, adhesion loss, and passage of woundexudates. Joints such as knee, elbow, ankle, and shoulder may undergo amovement which can sometimes result in articulation covering more than135° movements, leading to the challenges noted above.

In a bent position, the skin around the knee can stretch up to 50%axially (i.e., parallel to the incision) and laterally (i.e., transverseor perpendicular to the incision). An incision closure appliance adheredto the skin in this area may preferably be able to provide enoughtension to close the incision yet accommodate the stretch with minimallocal stress. Minimizing the local stress may prevent local skinadhesion loss or damage to the skin if the adhesive loss does not occur.An important property for many incision closure appliances disclosedherein is the ability of the tension load of the appliance's closureelements to be distributed across an area larger than that of thetension element attachment point itself. Furthermore, the structurecomprising the adhesive to which the tensioning elements are attachedmay in many cases have the ability to distribute the compliance of thestructure across the region of skin stretch such that the applianceholds the incision in place while the skin moves around it. Embodimentsdescribed herein may include a composite design of non-stretchingtension elements (commonly referred to as “straps”) that are linked to“locks” that hold the straps in place. For example, such elements mayinclude the lateral tie assemblies 122 described above. These elementsmay be mounted over skin adhesives with elastic polymeric materials thathelp distribute the tension load. Such elastic polymers may in manycases have high elongation before yielding or permanently deforming andmay include thermoplastic elastomers such as polyurethane as well asvarious grades of silicone. Such materials may also be easily formedinto thin films necessary for maintaining a low profile and sufficientcompliance.

The skin adhesive used in the appliance may also need to withstand theelongation of the skin and be able to retract/recoil when the skin isreturned to an un-stretched condition (e.g., in the fully extended kneeposition). Hydrocolloid adhesives may provide such properties and may bepreferably suited for this application. Other adhesives such as acrylicmay also be used to provide this property. In general, such adhesivesmay need to be attached to an elastic thin film such as that describedabove in order to hold their structure during expansion and recoil.Without such support, the adhesive may tear and separate with repeatedelongation.

Incision closure appliances constructed as a sequence of short segmentsmay accommodate higher overall elongation without loss of adhesion orskin damage. Each individual segment may be subjected to the localstretching of the skin under it. The space between two adjacent segmentsmay act as stress relieving space allowing the skin to stretch in thatspace. The segmentation may be achieved in number of ways: (1) by layingdown individual segments along the incision line, or (2) allowing thedevice to divide into short segments as it is applied to the skin orafter applying to the skin.

A preferred means of achieving segmentation after application to theskin comprises creating perforations (e.g., a lateral line ofperforations to facilitate tearing) in the polyurethane layer (i.e., theupper layer 106, 110 of a base panel 102, 104) and leaving theunderlying adhesive intact. The perforations may result in tearing of atleast the upper layers (e.g., upper layers 106, 110) of the base panelsalong the perforated lines (e.g., lines 124, 126) when it undergoesstretching as the knee flexes (i.e., is articulated). In preferredembodiments, the adhesive panel on each side of the incision may be 12mm wide, and the perforations within a given panel are spaced about12-20 mm apart. Experimentation was performed and showed that aperforation of 3 mm cut and 1 mm tie distances are effective inachieving segmentation in 0.001 inch thick urethane base panels when theknee flexes. As the knee flexes, the skin may elongate in axial (alongthe incision) and lateral directions up to 50% in some locations.Separation of the polyurethane can thus relieve stress in the device asit undergoes stretch.

As an example, a surgically repaired knee may be inflamed for a numberof days, which may result in approximately 30% radial swelling of thejoint after closure. Elastic materials like polyurethane may allow theincision closure appliance to expand with this circumferential swelling.Minimizing the width of the appliance (e.g., 12 mm or less for each basepanel segment 102, 104) may minimize the amount of the appliance subjectto expansion in a direction perpendicular to the incision, and may thuspreserve adhesion while minimizing potential for skin damage.Perforations in adhesive segments running in the lateral direction tothe incision along lines may allow the base panels to stretch moreeasily axially. Perforations or other fenestrations could also be madenear the outer edges of the adhesive segments parallel to the incisionin order to reduce the stress incurred as the skin stretches radiallyoutward from the incision such as during articulation and swelling.

Perforated segments of base panel upper layers, typically comprisingpolyurethane, may be held together with a continuous layer of theadhesive bottom layer, typically comprising a hydrocolloid adhesive, toallow laying down on the skin in one continuous motion. The incisionclosure appliances 100 may be provided with such a continuous adhesivebottom layer.

The base assembly or base panels of the incision closure appliancesdescribed herein preferably may be covered with a flexible adhesive filmmaterial at the end of a wound or incision closure. This film areapreferably may be larger than the base incision closure panel elementssuch that it overlaps the elements onto the skin. The film may helpprevent migration of the base and may prevent any accidental movementsof the anchors and locking mechanisms. The cover film may be made fromstretchable materials like rubber, latex, polyurethane, silicone orthermoplastic elastomer, etc. In preferred embodiments, a thin cover(e.g., laminate of 0.001″ urethane and 0.002″ thick acrylic adhesive),will have a greater compliance than the composite structure of the basepanel elements. As a result, the cover may offer some strain reliefbetween the exposed skin and the base segments. The cover may also betransparent to allow visual inspection of the incision. The cover maycompletely seal across the incision (e.g., as a barrier to infection) orthere may be openings in the cover that are aligned with the incisionline to allow passage of any exudates from the wound. The cover may alsoserve to improve the apposition of the incision edges by bridging thebase panels and adhering to the skin edges between the base strips. Thecover may also be constructed with additional reinforcing elements thatimprove the tensile strength between the base panel elements but allowfor compliance along the incision length. A preferred embodiment maycomprise a series of polyethylene adhesive tape strips applied to thecover.

While the user may apply the cover after the base assembly and panelsare placed on the skin, it is also conceived that the cover material maybe supplied as a “skirt” extending around the outer perimeter of thebase segments. Thus, alignment of the cover materials relative to thebase may not be dependent on the user placement. These same covermaterials may provide the effects of preventing exposure of thehydrocolloid adhesive to patient clothing, limitation of migration ofthe hydrocolloid or other adhesive lower layer, providing strain relieffor the tension on the base segments, etc.

In many embodiments, a hydrocolloid adhesive is used for tensioning skinfor incision closure. The hydrocolloid may be prevented from creep byone or more of (1) using a laminate on the surface to limit creep or (2)applying an adhesive cover across the skin and the hydrocolloid adhesiveto prevent creep and to provide strain relief to the skin to preventskin damage.

In many embodiments, a cover as used with the base assembly may includeone or more of perforations or openings to allow removal of woundexudate (as well as any applied bandages/absorbent material) withoutremoval of the adhered base assembly.

In many embodiments, the cover comprises a composite of flexibleurethane and reinforced strips. The composite construction may providestrength across the incision as well as provide for compliance along theincision length.

In many embodiments, the cover in combination with the base assemblyaligns the skin incision edges or significantly prevents subsequentmisalignment of the skin edges, in both the axial and lateraldirections.

In many embodiments, cover liner configurations are provided such thatpart of the cover can be applied to the skin first, which then aids inthe removal of other liners and thus may help control the thin materialsso they lay out evenly with minimal wrinkling.

In many embodiments, the removal of a first liner may allowvisualization during placement and may prevent the remainder of thedevice from sticking to the user.

The skin adhesive used for each panel 104, 106 may preferably comprise ahydrocolloid adhesive. Alternatively or in combination, the skinadhesive may comprise one of many acrylic formulations known in the art.Hydrocolloid adhesives may have the benefit of being very tacky and ableto absorb moisture and shedding skin cells. Thus, hydrocolloid adhesivesmay be particularly suited for long-term wear applications (e.g., up to14 days). In at least some instances, the hydrocolloid structure may besoft, however, and may be prone to creep under tension unless reinforcedin some manner such as by covering the hydrocolloid adhesive layer withstiffer base panels 102, 104 or other covering structures disclosedherein.

Accordingly, a further aspect of the present disclosure also providesvarious means of reinforcing and protecting the adhesive layer in thebase assemblies of the incision closure appliances described herein aswell as additional means of holding the skin edges together,particularly in the axial direction. In at least some cases, thehydrocolloid adhesive alone has very low tensile strength and mayrequire a means of reinforcement to prevent it from tearing or creepingduring use. As illustrated in FIG. 1D, an adhesive layer 1211 used inbase panels 1104, 1106 of a closure device may be laminated with a thinlayer of a compliant plastic or polymer 1212, such as urethane,preferably 0.001 inch thick, with a potential range up to 0.010″ thick,that may help to maintain its structure during clinical use. Theadhesive layer itself may nominally be 0.010 inch thick, but may rangebetween 0.005 inch and 0.020 inch thick. Because tensioning elementscomprising straps 1130 or locks 1132 attached to a load distributioncomponent 1118 may be mounted to the top of the adhesive structure 1211,the possibility exists that the material could creep over time. Thelaminate 1212, as well as any other adhesive laminates 1215 a, 1215 bbetween the adhesive layer 1211 and the load distribution component1118, may help provide the structure to prevent creep of the adhesivelayer.

To further prevent migration of the adhesive panel 1211, a cover 1220may also be applied over the panels 1104, 1106 as shown in FIG. 1E1. Asshown in FIG. 1E2, the cover 1220 may comprise a thin, adhesive coatedcompliant elastomer 1221. In many embodiments, the cover 1220 furthercomprises a thin urethane layer (preferably 0.001 inch thick) coatedwith a skin adhesive, such as an acrylic adhesive (preferably 0.002 inchthick), which may be provided on one or more release liners 1223 a, 1223b. The cover may further comprise reinforcing features 1225.

As shown in FIGS. 1F1 and 1F2, the cover 1220 may be constructed suchthat it may extend beyond the base panels 1104, 1106, thereby bridging adistance, d3, between the skin S and the panels 1104, 1106. A typicalminimum necessary distance, d3, may be 8 mm but could range 2-15 mm.Besides helping prevent creep of the adhesive layer of the base panels1104, 1106, the urethane skin adhesive of the cover 1220 may also helpto strain relieve the tension applied to the base panels 1104, 1106 frommovement of the surrounding skin S. This may serve to prevent skindamage (e.g., from erosion or blistering) at the base panel 1104, 1106edges. It should be noted, however, that the compliant nature of thehydrocolloid offers local protection from blistering by itself beingable to move with the skin S and thus resist damage to the skin S. Inmany embodiments, even with stiffer structures mounted to the outersurface of the adhesive layers, the compliance within the nominal 0.010″thickness of the adhesive layers down to the skin surface may provideresistance to skin damage.

Besides stabilizing and strain relieving the base panel structures, thecover 1220 may serve other purposes. By covering the location where astrap 1130 would engages a lock 1132, the cover 1220 may prevent thepatient from tampering with the locks 1132 to the point where the straps1130 could be disengaged. As shown in FIGS. 1F1-1F2, the cover 1220 maybe fitted with openings 1224, 1224′ along the length of the regionoverlapping an incision, such that externally applied gauze may absorbwound exudate. In other embodiments, the cover 1220 may not haveopenings in order to protect the wound from sources of infection. Thecover 1220 itself may have reinforcing features 1225, 1225′ to providethe base 1102 with additional resistance to the incision opening,particularly in regions between the straps 1130. FIG. 1F3 shows aparticular embodiment where the reinforcing features 1225′ could berectangular strips of adhesive tape. The tape 1225′ may preferably bestiffer perpendicular to the skin incision than the surroundingcompliant urethane layer 1221. The tape 1225′ may be constructed fromany combination of adhesive coated woven fabric, polymer fibers,polyethylene, polypropylene, nylon, PET, hydrocolloid, or othermaterials known in the art. The reinforcing features 1225′ may also add“body” or stiffness to the cover 1220 to aid in its placement. Theurethane layer 1210 may be constructed of such materials to give it abi-directional stretch.

The spacing of the reinforcing features 1225, 1225′ may be important toensure the longitudinal (parallel to the incision line) compliance ofthe cover 1220 (e.g., due to the compliant thin urethane). This mayserve to improve patient comfort and the resistance to skin damage byallowing the cover 1220 and the underlying base assembly 1102 to movewith motions of the body. This effect may be from the cover 1220 aloneor as a composite effect with features on the base assembly 1102 whichmay allow longitudinal compliance. The reinforcements 1225, 1225′ mayalso be of a uniform construct, but perforated, slit, or otherwisemechanically interrupted to allow stretch and/or controlled tearing withbody motion. The thin urethane layer(s) of the cover 1220 may also bemechanically interrupted to the same effect. In at least some cases, thereinforcing features 1225, 1225′ of the cover 1220 may not extend theentire width (perpendicular to incision) of the cover 1220. This limitedcovering width may help ensure strain relief to the body motion awayfrom the base assembly 1102 perpendicular to the incision I. Inpreferred embodiments, the region of the cover 1220 reinforced by thereinforcement members 1225, 1225′ extends 10 mm in each direction awayfrom the incision edge, but this may range from 2-50 mm.

Another feature of the cover 1220 may be to be able to add control tothe incision edge, particularly between the tensioning elements 1130,1132 of the base assembly. As illustrated in FIG. 1G1, the tensioningelements 1130, 1132 combined with the base panels 1104, 1106 may serveto approximate the incision edges 1205 together. Once the skin S isapproximated, it may be important that the skin edges be alignedvertically (perpendicular to the skin surface). Vertical misalignmentmay lead to slower healing and visible “step-off”, or ledge, in theincision that may result in poor scar cosmesis. By having portions ofthe cover 1220 adhere to each edge of the base panels 1104, 1106 alongthe incision, each edge may held under tension in vertical alignment asshown by arrows 1201 a, 1201 b. Adhesive on portions of the cover 1220crossing the incision I may also adhere directly to the skin S at theincision edge, further shortening the distance between the adheredincision edges and further enhancing vertical skin alignment. Inpreferred embodiments, the portions of the cover 1220 crossing theincision I are rectangular strips 1225′ of adhesive tape as shown inFIG. 1F3. The width of each strip 1225′ and the axial gap between thestrips 1225′ may be optimized for incision edge control, incisionvisibility, and the escape of wound exudate. A preferred embodiment maycomprise a strip 12 mm wide and spaced 6 mm apart, with the strapslocated between each strip. Other widths and spacing are alsocontemplated. By not bridging/tenting over each strap 1130, the strip1225 may lay flatter against the skin S for better adhesion and edgecontrol.

In some embodiments, the reinforcing features 225, 225′ may beconstructed to limit the amount of bending at the incision site. Thereinforcing features 225, 225′ in these embodiments may be stiffer thanthe skin S, and preferably stiffer than the surrounding elements of thebase panels 104, 106. In this way, and bending or compression of theskin S through normal patient motion would be isolated, or thepropagation limited, around the incision site. While this motionisolation or limitation would help strengthen the incision site intension, a greater benefit may be to prevent the incision edges fromsignificantly or unevenly inverting, everting, or shifting in adirection perpendicular to the skin surface. Reinforcing materialsdiscussed above may be used, with the thickness tailored to create thedesired stiffness. Preferably, the composite of the base assembly 102and cover 220 may be constructed to create a smooth transition instiffness and compliance from the surrounding skin to the isolatedincision site.

In particular methods of use, after initial closure of the incisionusing the base assembly 1102 to approximate the skin edges, the basepanels 1104, 1106 may be pushed together further to “pooch” the closedincision I upward to slightly evert the edges and/or compress the skin Saround the incision edges to relieve tension. FIGS. 1H1-1H3 illustratean embodiment of this method in an in-vivo tissue model. FIG. 1H1 showsa step 1250A in which the base panels 1104, 1106 are adhered to the skinS adjacent an incision I and are pushed together to “pooch” the closedincision I upward. The base panels 1104, 1106 may be then pulledtogether further to hold the tissue in this orientation. These methodsmay be enhanced by positioning the base panels 1104, 1106 away from theincision edge by 5-10 mm. In a step 1250B shown by FIG. 1H2, the basepanels 1104, 1106 may be locked in place relative to one another withthe straps 1130 and the locks 1132. In a step 1250C shown by FIG. 1H3,the cover 1220 may then be applied to lock in the relative location ofthe base panels 1104, 1106 and “pooched” incision I. The incision Icould be further reinforced with the reinforcing elements 1225, 1225′discussed above.

A given cover 1220 may in many embodiments be fitted with release linersto aid in user handling of the cover 1220 before and during applicationto the patient. As shown in FIGS. 1E1 and 1E2, the cover 1220 may haverelease liners 1223 a, 1223 b applied in a three-part configuration. Theuser may first remove a longitudinal center liner 1223 b to apply thecenter exposed adhesive to the base assembly 1102 and skin incisionregion. Removal of this liner 1223 b first, in combination withvisualization through the clear plastic and/or openings in the center ofthe base 1220, may allow the user to see the base assembly 1102underneath such that the cover 1220 can be properly aligned with thebase assembly 1102 as the cover 1220 is applied. This may also helpprovide regions of the cover 1220 that do not stick to the user untilthe cover 1220 is initially secured to the base assembly 1102 and/or theskin S. Next, the side release liners 1223 a may be removed in adirection perpendicular to the incision I. The liners 1223 a hold andtension the very thin urethane to keep it from substantially wrinklingas it is applied to the skin S. Also, by sticking the center of thecover 1220 to the base assembly 1102 and/or the skin S first, the cover1220 may be held in place such that sufficient tension and control maybe applied to the side release liners 1223 a for smooth application ofthe remainder of thin adhesive coated cover 1220 to the patient.Alternatively or in combination, the liners may be constructed such thatthe first liner is removed to expose a narrow strip over the full widthof the cover 1220 (perpendicular to the incision I) to allow initialplacement on the base assembly 1102 and/or skin S, followed by removalof one or two additional liners in a direction parallel to the incisionI. The first liner may be in the middle of the length, on either end, orsomewhere in between. If not on the end, two additional liners may berequired, each removed in a direction from the location of the firstliner outward along the length of the device. If the first liner was onone end, a second single liner may be removed from the location of thefirst liner out toward the end of the device.

Another release liner configuration may be to have a single liner whichcould be completely removed from the bottom of the cover 1220 beforeapplication. This type of liner may require an outer film, or castingsheet, be lightly adhered to the outer surface of the cover 1220 to helpthe thin urethane hold its shape and provide the user with locations atthe sides and/or ends which do not have adhesive and thus would notstick to the user's hands during application. The outer film could beover the entire outer surface or just a particular width surrounding theperimeter of the cover 1220. The film and/or the release liner couldalso have an area extending beyond that of the thin urethane in thecover 1220. Once the cover adhesive is attached to the base assembly1102 or skin S, the casting sheet may be easily removed from the outsideof the cover 1220.

As described herein, flexible wound dressings and wound or incisionclosure devices or appliances are typically flexible and stretchable tofollow the contour of curved parts of the body (e.g., arm, longerincisions that are curvilinear, etc.) or the areas that undergostretching (e.g., knee). To assist the draping of such devices, abacking material may be used which assists in maintaining the dressingshape during the application. Such temporary backing material describedherein may have a number of advantages. The backing material may beclear to enable the visual of the wound. The material may benon-stretchable to prevent elongation of the dressing or closure deviceor appliance during application. The backing may be easily removableafter the application of the wound dressing or closure device orappliance so as to not affect the adhesion of the actual dressing on thewound site. The backing material may also assist in the handling of thedressing during manufacturing process. In many embodiments, the backingmaterial may couple to a dressing or closure device with peel-offrelease liners on the adhesive side of the dressing to enable easy andreliable removal of the backing material.

Referring now to FIG. 1I1, a wound dressing cover 2600 may comprise aflexible sheet 2610 made of a flexible material like rubber, urethane,silicone, etc. The flexible material 2610 may laminated on a relativelystiffer material in the form of a casting sheet or carrier layer 2620.The casting sheet 2620 prevents the flexible material 2610 from rollingonto itself and becoming unusable. The flexible sheet 2610 may have anadhesive on one side (e.g., the bottom side) and a relatively rigid(stiff) carrier layer or casting sheet 2620 on the other side. Theadhesive side is protected by two liners 2630, 2640 that can besequentially removed to expose the adhesive in a controlled manner. Toapply the dressing 2600 on the wound or incision, a small strip ofadhesive is exposed by removing one of the release liners, usually thesmaller release liner 2630. This release liner 2630 may be attached tothe casting sheet 2620 using a tape 2650. The exposed part of theflexible sheet 2610 may then be adhered at one end of the wound orincision. The flexible cover 2600 then follows the contour of the woundor incision and the curvature on the body as the second release liner2640 is slowly removed to expose the adhesive sequentially.

The first release liner 2630 which is typically still attached to thecasting sheet 2620 with the tape 2650 may then be used to lift thecasting sheet 2620 from the flexible dressing 2610.

A manufacturing process for the wound dressing cover 2600 and associatedliners 2630, 2640 may be to use a single die to cut a common profile(perimeter) of the laminate of the release liners 2630, 2640, theflexible dressing (with adhesive) 2610, and the casting sheet 2620. Uponremoval of the liners 2630, 2640 and application of the dressing sheet2610 to the skin, the casting sheet 2620 may remain on the dressingsheet 2610. Removal of the casting sheet 2620 may require initiation bydelaminating and peeling back an edge of the casting sheet 2620 from thedressing sheet 2610. Once initiated, the continued peel and removal ofthe casting sheet 2620 may be straightforward. Initiation and lift ofthe edge of the casting sheet 2620 may not always be intuitive and mayrequires a free edge connected to the casting sheet 2620 to helpidentify the lift point and begin the peel. The tape 2650 may be used tobridge the casting sheet 2620 to the release liner 2630 and may providean easily identifiable tab which can be used to initiate the peel.

Alternative configurations of the casting sheet 2620 may be used toinitiate the peel of the casting sheet 2620 as shown in FIGS. 1I2-1I5.

As shown in FIG. 1I2, the casting sheet die may be cut such that thecasting sheet 2620 a extends axially beyond the flexible dressing sheet2610 (e.g., the liners 2630, 2640 and urethane material of the flexibledressing sheet 2610 may be “kiss cut” to the surface of the castingsheet 2620 a).

As shown in FIG. 1I3, the casting sheet 2620 may have tape 2650 appliedto either one or both axial sides to extend beyond the casting sheet.The tape 2650 may not necessarily be attached to the release liner 2630.

As shown in FIG. 1I4, casting sheet tape 2650 may be attached at or nearthe axial edge(s) of the casting sheet 2620 and also extends inside theprofile of the casting sheet 2620, with a loose non-adherent edge 2652for the user to grasp.

As shown in FIG. 1I5, the casting sheet die may be cut (e.g., kiss cutsuch that the casting sheet 2620 is not cut into the flexible dressingsheet 2610) from one axial edge to a partial or full-length distance toanother axial edge of the casting sheet 2620. The cut casting sheet 2620may be separated with a “pinch” by the user to create an edge to grasp.The interior die cut edge may also have a tape or similar tab 2654applied to one or both of the interior edges to grasp and peel as shownin FIG. 115.

In many embodiments, the casting sheet 2620, 2620 a and/or tape 2650,2652, 2654 may be of a different color or have markings to distinguishfrom the flexible dressing sheet 2610 and release liners 2630, 2640.

One or more of the components of the incision closure appliances orincision closure appliance assemblies disclosed herein, including one ormore of the various base assemblies, base panels, force distributionstructures, axial supports, lateral supports, closure components, tieassemblies, straps, locks, adhesive layers, adhesive layers, covers,cover structures, drapes, etc., may be comprised of, be coated with, orotherwise incorporate one or more of an antifungal, antibacterial,antimicrobial, antiseptic, or medicated material. For example, suchmaterials may be incorporated into the hydrocolloid adhesive layer, asanother layer or coating between the skin and the adhesive layer(covering at least a portion of the adhesive layer), incorporated intothe base assembly cover or at least its adhesive layer, etc. One or morewells, grooves, openings, pores, or similar structures may be providedon the device or apparatus components to facilitate such incorporation.In many embodiments, such materials may comprise one or more of silver,iodide, zinc, chlorine, copper, or natural materials such as tea treeoil as the active agent. Examples of such antifungal, antibacterial,antimicrobial, antiseptic, or medicated materials include, but are notlimited to, the Acticoat™. family of materials available from Smith &Nephew plc of the U.K., the Acticoat™ Moisture Control family ofmaterials available from Smith & Nephew plc of the U.K., the Contreet™Foam family of materials available from Coloplast A/S of Denmark, theUrgoCell™ Silver family of materials available from Urgo Limited of theU.K. (a subsidiary of Laboratoires URGO of France), the Contreet™Hydrocolloid family of materials available from Smith & Nephew plc ofthe U.K., the Aquacel™ Ag family of materials available from ConvaTecInc. of Skillman, N.J., the Silvercel™ family of materials availablefrom Kinetic Concepts, Inc. of San Antonio, Tex., Actisorb™ Silver 220available from Kinetic Concepts, Inc. of San Antonio, Tex., the Urgotul™SSD family of materials available from Urgo Limited of the U.K. (asubsidiary of Laboratoires URGO of France), the Inadine™ family ofmaterials available from Kinetic Concepts, Inc. of San Antonio, Tex.,the Iodoflex™ family of materials available from Smith & Nephew plc ofthe U.K., the Sorbsan Silver™ family of materials available from AspenMedical Europe Ltd. of the U.K., the Polymem Silver™ family of materialsavailable from Ferris Mfg. Corp. of Burr Ridge, Ill., the Promogram™family of materials available from Kinetic Concepts, Inc. of SanAntonio, Tex., the Promogram Prisma™ family of materials available fromKinetic Concepts, Inc. of San Antonio, Tex., and the Arglaes™ family ofmaterials available from Medline Industries, Inc. of Mundelein, Ill.Components of the closure devices described in commonly owned U.S. Pat.Nos. 8,313,508, 8,323,313, and 8,439,945; U.S. Patent Publication No.2013/0066365; and PCT application nos. US 2010/000430, US 2011/139912,US 2011/40213, US 2011/34649, and US 2013/067024 and others incorporatedherein may also be comprised of, be coated with, or otherwiseincorporate one or more of an antifungal, antibacterial, antimicrobial,antiseptic, or medicated material, including but not limited to one ormore of the materials listed above.

In many embodiments, topical medicinal agents are incorporated directlyinto the wound closure appliances described herein. Because a woundclosure device is often applied in close proximity to a wound orincision in need of medicinal protection, the incorporation of suchmedicines directly into the closure device may be beneficial. In woundsat risk of infection, incorporation of anti-microbial agents may bebeneficial, for example. Anti-microbial agents may include antibioticmedicines as well as antiseptic metal ions and associated compoundswhich may include silver, iodine, copper, and chlorine, or naturalmaterials such as tea tree oil. In wounds prone to fungus, medicinalagents such as zinc may be warranted, for example. Combinations of anyof these agents may also be of benefit and thus may be incorporated intowound closure appliances.

Topical medicinal agents may be incorporated into the closure devices ina way to give the closure devices the ability to wick exudate away fromthe wound (e.g., to direct unwanted organisms away from the wound and/orprevent skin maceration), while keeping the wound sufficiently hydratedfor improved healing.

Coatings.

According to further aspects of the present disclosure, after assemblyof a closure device (such as closure device 100) a coating can beapplied to the outer surface to prevent adhesion to the wound dressing.An exemplary coating may utilize a non-stick fluoropolymer coatingapplied and cured to the device 100, typically with a process that doesnot require temperatures exceeding 60° C. for 5 min., and morepreferably under 45° C. for any period of time. The adherence of thecoating with the polyurethane film of the wound closure device may bemost desired, though protection of all external surfaces may bedesirable as well. The fluoropolymer film thickness may range from 0.25to 5.0 microns, preferably about 1-3 microns. Coating would typicallytake place with release liners or other suitable material in contactwith the skin adhesive surface to prevent contamination of the skinadhesive with the coating. Such a coating would typically be applied aspart of the manufacturing process such that no additional coating isrequired to be applied by the user. However, in other embodiments, justbefore dressing application, the user may instead apply a preferablysterile oil-based liquid or gel to the outside of the Zip device toprevent adhesion. Examples include petrolatum and silicone oil.

Other coatings that do not require cure temperatures that can damage thedevice adhesives (typically above 60° C.) may be applied. These mayinclude silicone compounds or oils (cured to the material or uncured),parylene, and other coatings well-known in the art. The coating maypreferably remain bound to the closure device upon removal of thedressing, though could also act by deadening the applied adhesive,and/or acting as a sacrificial layer that is pulled up with the dressinginstead of the underlying device. Sacrificial coatings may be thicker,more in the range of 0.0005″-0.010″.

While preferable to apply to the entire finished device, the coatingcould be applied to selective regions of the device by masking areas tonot be coated. This may be useful if coating is incorporated into anintermediary process where component bonding must be subsequentlyperformed to non-coated regions of the device, or if coating of othercomponents (e.g., the locks and straps) results in undesirable lowfriction (e.g., straps don't stay engaged in locks or strap slips out ofuser's hands). In other cases, the coating may be on a material that isapplied separately to the device (e.g., a strip of polyurethane film).This may be useful if the coating process requires an elevatedtemperature or use of solvents that are incompatible with the rest ofthe device.

In other embodiments, the coating material may have an antimicrobialcompound incorporated into the coating. The coatings described above arepreferably conformal to the device surfaces and remains adhered to theclosure device at least until the wound dressing is applied. Thecoatings described also offer minimal resistance to closure devicestretch (up to 50%) and themselves do not loose protective effects whilethe dressing is worn against the closure device.

Low Tack Adhesive Protective Strips.

According to further aspects of the present disclosure, one or moreremovable protective strips 201 of material (also referred to as“dressing shields”) may be applied over the closure device 100 toprotect the closure device from the adhesive of any wound dressing, asillustrated in FIGS. 2-5 for example. The protective strip(s) 201 mayact as a sacrificial layer. The protective strip(s) 201 are preferablyconstructed from a material that does not stick to the underlyingclosure device 100. Each strip 201 may preferably be coated on the sidefacing the closure device 100 with the material that prevents adhesionto the closure device 100. The strip 201 may preferably be constructedfrom an elastic material 201 a, for example, polyurethane, and may becoated with an adhesive 201 b formulated and/or constructed to havelower tack to the closure device 100 than the closure device 100 has toskin, thus ensuring removal of the strips 201 does not disrupt adhesionof the closure device 100 to the skin. The strip 201 may be comprised ofa single material layer with no adhesive, two layers where one layer isan adhesive or non-stick coating, or more than one material layer withthe multiple layers laminated using heat or by incorporating a layer ofadhesive between the layer(s), wherein the laminate adhesive may or maynot be the same as the adhesive facing the closure device 100. In someembodiments, the strip 201 is a composite of elastic fibers, elasticfilm, and elastic adhesive. The strip 201 may comprise perforations,notches, cutout spaces (e.g., holes), and the like sufficiently sized tomaximize elasticity and breathability of the strip 201 while minimizingthe degree of adhesion from the dressing. The strip material may alsocomprise of a blown polyurethane film that is more elastic and porousfor a given thickness than non-blown films, or other breathablenon-woven material known in the art, typically fabricated frompolyester, polyethylene, and polypropylene. The non-woven material maybe constructed to be air permeable but not liquid permeable (withoutapertures) or may incorporate apertures for very high breathability andmoisture transfer. The material could also be constructed from a wovenfabric, preferably containing elastic fibers and/or antimicrobialcoatings known in the art. Providing a very thin material (approximately0.0005″-0.001″) can aid in breathability and conformability, whilethicker films or fabrics (up to approximately 0.025″) may aid in userhandling. The optimal design thickness may be in-between depending ondesired elasticity and materials and construction chosen.

The strips 201 may be designed to ensure protection of the closuredevice but not interfere with the contact of the dressing with the woundor incision. As shown in FIG. 2, the outside of the strip 201 should notextend further than necessary beyond the outer perimeter 100 c of theclosure device 100 in order to maximize dressing contact with the skin.For a closure device 100 having a panel width of 17.5 mm, a 25 mm widestrip may be preferable to ensure optimal overlap of the strip and allowtolerance for hand alignment by the user. The strip length may beprovided long enough to overlap the full length of the closure device100 by approximately 5 mm on each end. The strip 201 may preferably bemade from a material (e.g., thin polymer films) that can be trimmed tothe desired length with surgical scissors.

In some embodiments, as shown in FIGS. 3A and 3B, the strip 201 maycomprises a 0.001″ thick elastomeric film such as polyurethane film 201a coated with a 0.011″ thick silicone adhesive as a gel or pressuresensitive adhesive 201 b. The adhesive layer 201 b may be protected witha release liner 301 until use. The silicone adhesive may preferably beconstructed to be low tack such that it does not disrupt the closuredevice adhesive during removal. This may be achieved with the chemicalformulation and/or by crosslinking the adhesive using irradiation suchas electron beam or gamma. The silicone could also be formulated to befully cured and/or cross-linked to have no adhesive properties.

In some embodiments, similar to the sacrificial cover strip assemblyshown in FIGS. 3A and 3B, the strip 201 may comprise a 0.002″ thickpolyurethane film 201 a with a low-tack 0.002″ thick acrylic or urethanepressure sensitive adhesive (PSA) 201 b applied to one side. The strip201 may be supplied to the user with a release liner 301 to protect theadhesive until ready for application. The low-tack adhesive isformulated to be releasable from the surface of the closure device 100(and patient's skin) before the closure device releases from the skin.

In some embodiments, illustrated in FIGS. 4A-5, a 25 mm wide strip 201may comprise of a first 0.001″ thick polyurethane film 201 a and asecond 0.001″ thick polyurethane film 201 c of the same size laminatedto the first with a 0.002″ acrylic PSA layer 201 b therebetween. Thesecond film 201 c may be constructed to have notches 202 along the outerperimeter removed such that the PSA 201 b may be exposed on one surfacein the notch locations. As illustrated in FIGS. 4A-4C, the notches 202may be approximately 2 mm×3 mm in size and spaced approximately 10 mmapart. By both controlling the notch size and recessing the adhesivebelow the surface of the second layer 201 c, the strip 201 may providethe desired low tack sufficient to hold it in place against the closuredevice 100 and the desired release force of the strip 201 from theclosure device 100 and skin. This may also allow the use of relativelystrong PSA (e.g., the same formulation as used on the closure device100) that will still release from the closure device 100. Othercombinations of film thickness, notch size, cutout space, and adhesivestrength may be achieved to a similar result. In other embodiments, thenotches 202 or cutout spaces may be other shapes such as circles forholes, or may be closely spaced gaps between film strips 201.

In some embodiments, shown in FIGS. 6A-6C, a single strip assembly 400may be configured to cover the entire closure device 100 instead ofcomprising of the separate strips discussed previously. The single strip400 may be provided with apertures 407 such that wound exudate may passthrough the strip where it covers the incision. As illustrated in theexploded view of FIG. 6B, the strip assembly 400 may comprise an outersupport film 405 lightly adhered to the outer surface of the stripmaterial 406 to aid in placement of the strip. The support film 405 maythen be removed by the user after placement. The support film 405 may beconstructed from paper, polyethylene, or other suitable material. Thesupport film 405 may preferably extend beyond the border of the strip406 to aid in handling, but may also be die-cut to the same perimeter asthe strip material 406. Similar to previous embodiments, the strip 400may be provided with an adhesive layer, preferably a low-tack siliconeadhesive as a gel or PSA protected by a release liner 408 until use. Asillustrated in FIG. 6C, the apertures may preferably be approximately1.0 mm in diameter and spaced approximately 2.5 mm apart for ˜13%aperture exposure. The size and spacing of the apertures 407 may bevaried to optimize exudate passage against protection of the closuredevice 100 surface. The aperture size and space may also be varied tooptimize the low-tack silicone adhesive adhesion to be releaseable fromthe surface of the closure device 100 (and patient's skin) before theclosure device 100 releases from the skin.

FIGS. 7A and 7B show a single strip assembly 401 a similar to the singlestrip assembly 401 described above with respect to FIGS. 6A-6C. Thesingle strip assembly 401 a does not use a support frame 405. Therelease liner 408 in any of the above embodiments may incorporate asplit or crack to aid in removal of the strip 406 from the release liner408.

In embodiments similar to the above, the adhesive is applied to a singlefilm (or film composite) in an interrupted pattern and/or discrete areasto minimize the total adhesive surface area to achieve low tack andoptimal breathability.

For the above closure device protection embodiments, the method ofapplication may be similar.

In a first step, the closure device may be applied to the patient, theclosure device may be closed and have their straps cleaned, and thewound area may be cleaned.

In a second step, protective strip(s) 201 may be removed from therelease liner 301 and applied over the outside of each base panel of theclosure device 100 (e.g., base panels 102 and 104). The outer edges ofthe closure device 100 may be overlapped by the protective strip. Theprotective strip(s) may be lifted and repositioned as necessary.

In a third step, the wound dressing may be applied to the outside of theclosure device 100 having the protective strips 201 in place.

In a fourth step, the wound dressing may be removed. The wound dressingmay be removed prior to the removal of the closure device 100. Theprotective strips 201 may be removed along with the dressing, leavingthe closure device 100 intact and adhered to the skin.

In a fifth step, if another dressing is required, new protective strips201 may be placed over the closure device 100 and repeat the third stepabove may be repeated.

A protective layer similar to those described above with reference toFIGS. 6A-6C and FIGS. 7A-7B may be incorporated directly into the wounddressing to prevent the wound dressing from adhering to the closuredevice 100. FIGS. 8A-8B illustrate an exemplary island dressing 500which may comprise a protective layer 504. The protective layer 504 maybe similar in material and design as those described above withreference to FIGS. 6A-6C and FIGS. 7A-7B, except that the protectivelayer 504 may be adapted to be adhered to the exudate absorption layer503 using PSAs, heat welding processes, or stitching techniques.Apertures in the protective layer 504 may allow passage of exudate intothe absorption layer or exudate pad 503. The island dressing 500 mayalso include a skin adhesive layer 502 and protective film 501 to whichthe exudate pad 503 is adhered. Release liners 505 may protect the skinadhesive 502 and protective layer 504 until use. The protective layer504 may also be of a construction similar to the sacrificial cover stripassembly 300 described above with reference to FIGS. 3A-3B, where twostrips (each of which may or may not contain apertures) are adhered tothe layer 503, with gap between the strips intended to align closelywith the incision and encourage unimpeded passage of exudate.

As illustrated in FIGS. 9A-9B, a dressing 510 may be provided in twoparts, first part 511 and second part 512. The first part 511 may beprovided in a construction similar to that of dressing 500 in FIGS.8A-8B, except that a short release liner portion of 505 is provided oneach end, with a longer release liner between. This first part 511 maybe cut transversely by the user into two parts 511 a and 511 b at adesired location between the short release liners. Alternatively, thefirst part may be provided to the user pre-cut in two parts 511 a and511 b as illustrated in FIG. 9B. The user may then trim one or both ofthe two cut first parts to a shorter length as desired, such that thetwo cut lengths are shorter than the total closure device length by anamount less than the length of the provided second device part 512. Asillustrated in FIG. 9C, a selected first part 511 a may be applied tothe skin overlapping one end of the closure device, after first removingthe small release liner. The remainder of the longer release liner canthen be removed and the remainder of the cut first part 511 a is adheredover the incision and Zip device. The remaining cut first part 511 b isthen applied in a similar manner beginning at the opposite end of theincision and closure device. The second part 512 may then be appliedover the gap 513 between the two applied first parts such that thesecond part overlaps the ends of the two cut first parts. The advantageof this configuration and application technique may be that the user mayeasily center the cut first parts of the dressing over the closuredevice. Another advantage can relate to placement over a joint. The twocut first parts may be applied over the ends of the incision on eitherside of the joint in a manner that relatively few folds in the dressingare required. The uncovered section over the joint may then be coveredwith the shorter second part where the folds are more easily managed.Managing the folds can be important to minimize folds and to tightlycrease them to minimize ingress or egress of fluids or othercontamination in spaces formed by the folds.

While preferred embodiments of the present disclosure have been shownand described herein, it will be obvious to those skilled in the artthat such embodiments are provided by way of example only. Numerousvariations, changes, and substitutions will now occur to those skilledin the art without departing from the scope of the present disclosure.It should be understood that various alternatives to the embodiments ofthe present disclosure described herein may be employed in practicingthe present disclosure. It is intended that the following claims definethe scope of the invention and that methods and structures within thescope of these claims and their equivalents be covered thereby.

What is claimed is:
 1. A system for closing an incision or wound, thesystem comprising: a closure device comprising first and second adherentbase panels, wherein each of the first and second adherent base panelscomprises a plurality of force distribution structures distributed alonga length thereof, and wherein the first and second adherent base panelsare coupled to one another by a plurality of lateral ties coupled toeach of the force distribution structures of the first and secondadherent base panels that are laterally adjacent one another; asacrificial cover strip assembly for placement over the closure devicewhen adhered to skin adjacent the incision or wound, the sacrificialcover strip assembly comprising one or more sacrificial cover stripshaving an adherent bottom surface and a release liner coupled thereto; afirst wound dressing configured to be positioned over the sacrificialcover strip assembly at a first longitudinal portion of the closuredevice; and a second wound dressing configured to be positioned over thesacrificial cover strip assembly at a second longitudinal portion of theclosure device, the second longitudinal portion being opposite the firstlongitudinal portion; wherein the first and second wound dressings arelongitudinally separate from each other such that a gap existstherebetween to allow longitudinal separation when the closure devicestretches longitudinally; wherein the one or more sacrificial coverstrips comprise adherent upper surfaces having a first adhesive tack,and wherein the adherent bottom surfaces of the one or more sacrificialcover strips comprise a second adhesive tack less than the firstadhesive tack so that the first and second wound dressings are eachremovable from the sacrificial cover strip assembly while leaving theclosure device adhered to the skin.
 2. The system of claim 1, whereinperimeters of the one or more sacrificial cover strips are greater thanperimeters of the first and second adherent base panels such that whenadhered thereto, the one or more sacrificial cover strips can extendbeyond the perimeters of the first and second adherent base panels. 3.The system of claim 1, wherein full lengths of the one or moresacrificial cover strips are greater than full lengths of the first andsecond adherent base panels such that when adhered thereto, the one ormore sacrificial cover strips can overlap the full lengths of the firstand second adherent base panels.
 4. The system of claim 1, wherein theone or more sacrificial cover strips comprise one or more perforations,notches, or cutout spaces.
 5. The system of claim 1, wherein the one ormore sacrificial cover strips comprises a pressure sensitive adhesivelayer.
 6. The system of claim 1, wherein the one or more sacrificialcover strips each comprise a first polyurethane layer, a secondpolyurethane layer, and a pressure sensitive adhesive layertherebetween.
 7. The system of claim 1, wherein the closure device iscoated with a low friction or non-stick coating cured thereon.
 8. Thesystem of claim 7, wherein the low friction or non-stick coatingcomprises a non-stick fluoropolymer coating, a silicon compound, asilicone oil, or parylene.
 9. The system of claim 7, wherein the lowfriction or non-stick coating has a thickness of 0.25 to 5.0 microns.10. The system of claim 7, wherein the low friction or non-stick coatingis stretchable.
 11. The system of claim 1, wherein the one or moresacrificial cover strips includes a second release liner.
 12. The systemof claim 11, wherein the release liner and the second release liner aresequentially removable to expose the adherent bottom surface.
 13. Thesystem of claim 1, wherein the one or more sacrificial cover stripscomprises a plurality of apertures configured to allow wound exudate topass through the one or more sacrificial cover strips.
 14. The system ofclaim 13, wherein each aperture has a diameter of about 1.0 mm.
 15. Thesystem of claim 13, wherein the plurality of apertures are spaced about2.5 mm apart from each other.
 16. The system of claim 1, furthercomprising a plurality of reinforcement features configured to beapplied to the one or more sacrificial cover strips.
 17. The system ofclaim 16, wherein the plurality of reinforcement features comprise aplurality of strips of adhesive tape.
 18. The system of claim 1, whereinthe plurality of lateral ties and the plurality of force distributionstructures have a serpentine arrangement that laterally spans the firstand second adherent base panels.
 19. The system of claim 1, wherein eachof the plurality of lateral ties comprises a ratchet mechanism.
 20. Asystem for closing an incision or wound, the system comprising: aclosure device comprising first and second adherent base panels, whereineach of the first and second adherent base panels comprises a pluralityof force distribution structures distributed along a length thereof, andwherein the first and second adherent base panels are coupled to oneanother by a plurality of lateral ties coupled to each of the forcedistribution structures of the first and second adherent base panelsthat are laterally adjacent one another; a sacrificial cover stripassembly for placement over the closure device when adhered to skinadjacent the incision or wound, the sacrificial cover strip assemblycomprising a first sacrificial strip covering the first adherent basepanel and a second sacrificial cover strip covering the second adherentbased panel, each of the first and second sacrificial strips having anadherent bottom surface and a release liner coupled thereto; a firstwound dressing configured to be positioned over the first sacrificialcover strip assembly at a first longitudinal portion of the closuredevice; and a second wound dressing configured to be positioned over thesecond sacrificial cover strip assembly at a second longitudinal portionof the closure device, the second longitudinal portion being oppositethe first longitudinal portion; wherein the first and second wounddressings are longitudinally separate from each other to allowlongitudinal separation therebetween when the closure device stretcheslongitudinally; wherein the first and second sacrificial cover stripseach comprise adherent upper surfaces having a first adhesive tack; andwherein the adherent bottom surfaces of the first and second sacrificialcover strips comprise a second adhesive tack less than the firstadhesive tack so that the first and second wound dressings are eachremovable from the sacrificial cover strip assembly while leaving theclosure device adhered to the skin.